Flame retardant resins comprising phosphorus containing flame retardants

ABSTRACT

Resin compositions comprising flame retardant materials obtained by heating phosphonic acid salts at temperatures above 200° C., have excellent properties and exhibit manageable curing behavior. Laminates, composites, molded articles and the like, which have excellent flame retardant properties and physical characteristics, are readily prepared from the resin compositions of the invention.

Resin compositions comprising flame retardant materials obtained byheating phosphonic acid salts at temperatures above 200° C. exhibit goodcuring behavior to produce materials, including laminates, composites,molded articles and the like, which have excellent flame retardantproperties and physical characteristics.

BACKGROUND

Epoxy resins have long been used in various industrial applications,many of which must meet demanding performance criteria. For example,epoxy compositions are often used in the formation of compositematerials and laminates, such as in the production of electricallaminates used in printed circuit boards (printed wiring boards, PWB). Arequirement of this application, and many other applications, is highlyflame resistance materials are required, and often a fire retardancylevel of V-0 in the standard Underwriters Laboratory test method UL 94is mandated.

Many types of flame retardant substances are known and many have beenused in such applications, but the most commonly used materials to datehave been halogen containing compounds, such as tetrabromobisphenol A.Typically, in order to reach the desired fire retardancy level (V-0 inthe standard “Underwriters Laboratory” test method UL 94), levels ofsuch bromine-containing flame retardant substances are required thatprovide a bromine content from 10 weight percent to 25 weight percentbased on the total weight in the product.

There is an increasing interest in non-halogen containingflame-retardants that can not only provide the necessary flameretardancy, but which do so without having a negative impact onprocessing or physical characteristics such as mechanical properties,toughness, solvent and moisture resistance, etc. In certain applicationsthe cure rate of an epoxy resin is an important consideration, e.g., ashort cure time has obvious advantages in any manufacturing process butin some instances an epoxy composition may cure too quickly to allow forrobust or exacting processing conditions. A flame retardant materialthat does not negatively impact on any of these important criteria isdesirable; a flame retardant material that can enhance a desirablecharacteristic is highly desirable.

Phosphorus based flame retardants have been used as alternatives tohalogenated flame retardants. Alkyl and aryl substituted phosphonic acidesters are compatible with epoxy resins but they are known plasticizersthat can lower glass transition temperatures of some cured epoxycomposition to unsatisfactory levels. They can also cause the resultingcured epoxy resin to absorb moisture, which can be very detrimental inmany applications such as electrical laminates. Other phosphorus basedflame retardant materials are known, for example, EP 0 754 728 disclosesa cyclic phosphonate, EP 1 116 774 discloses the use of a hydrogenphosphinate, 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, inconjunction with triphenylphosphine oxide, but their use in some epoxyapplications is often limited by process or performance difficulties orby increasing the costs of manufacture.

Phosphine oxide flame retardants have been used in epoxy resins.Phosphine oxide compounds containing reactive groups are known which arecapable of being bound to a polymer, either into the backbone orattached to a pendant chain. For example, U.S. Pat. Nos. 5,817,736;5,759,690; 5,756,638, 5,648,171; 5,587,243; 5,576,357; 5,458,978;5,376,453; and 5,036,135 disclose the incorporation of a phosphorusbased flame retardant compound into an epoxy resin, which is then curedwith an amino cross-linker such as dicyandiamide, sulfanilamide, and thelike.

U.S. Pat. Nos. 6,733,698; 6,740,732; 8,404,161; and 8,865,862 disclosehydroxyarylphosphine oxide flame retardants which can react with epoxygroups and serve as cross linkers for epoxy resins. Alternately, thesecompounds can be derivatized prior to incorporation into epoxy resins,for example, reaction between the phenoxy group and epichlorohydrinprovides a useful epoxy functionalized material.

U.S. Pat. No. 6,403,220 and U.S. Pat. No. 6,645,631 disclose a generalprocess for the preparation of electrical laminates useful in printedcircuit boards, which process comprises (1) applying or impregnating anepoxy-containing formulation onto or into a substrate, such as a wovenor nonwoven fiber mat containing, e.g., glass fibers or paper, whichsubstrate is then (2) heated at a temperature sufficient to draw offsolvent from the epoxy formulation and optionally to partially cure theepoxy formulation. This heating step is known as “B-staging” and theproduct is known as a “prepreg”, which, as a result of “B-staging”, ismore easily handled in the subsequent manufacturing steps wherein (3)one or more sheets of prepreg are stacked or laid up in alternatinglayers with one or more sheets of a conductive material such as copperfoil, if an electrical laminate is desired, and pressed at elevatedtemperature and pressure for a time sufficient to cure the resin andform a laminate. Common temperatures for the “B-staging” step are fromabout 90° C. to about 210° C. for a time ranging from about 1 minute toabout 15 minutes, but other temperatures and times can be used.

The formation of laminates can be a very exacting process. Onedifficulty encountered in preparing laminates such as those found incircuit boards, is that some curable epoxy compositions have gel times,i.e., the time period during which a prepreg remains partially cured andeasily handled, of less than 180 seconds, sometimes much less, asobserved by the stroke cure test, which complicates production ofprepregs and the final laminates. Gel times of greater than 250 seconds,for example 300 seconds or greater are much more desirable. Some epoxyresin formulations cure at an unacceptably fast rate to allow for properhandling. Copending U.S. patent application Ser. No. 13/455,414discloses that certain phosphorus containing salts that are also knownas flame retardants, e.g., salts of phosphinic acids, can retard thecure rate of epoxy compositions when used at very low levels, e.g., lessthan 2 wt %. Of course one does not want overly extend the curing timefor commercial and quality reasons.

Other flame retardants derived from phosphorus containing acids andsalts are known. For example, copending U.S. patent application Ser.Nos. 14/337,500 and 14/592,472, disclose that products obtained byheating certain alkylphosphonic acid metal salts, such as aluminumsalts, calcium salts, zinc salts etc., at temperatures in excess of 200°C. are thermally stable at temperatures above 400° C. and are readilyincorporated onto polymer compositions to provide excellent flameretardant properties. It has been found that these highly stable andcompatible flame retardants can be added to many epoxy compositions atlevels up to 50% and often higher, e.g., 55% or 60% by weight in astraightforward manner without interfering with processing, withoutvolatizing or exuding from the cured or precured composition, withoutnegatively impacting desired physical properties, while having anegligible effect on cure rates. Higher concentrations of the flameretardant in certain resins are possible depending on the resinformulation, the processing or application methods and the physicalproperties of the pre-cured and cured resin. These compositions aretypically halogen free and are well suited for use in preparing, highlyflame retardant laminates, composites and the like, including e.g.,circuit boards and prepregs for circuit boards.

SUMMARY OF THE INVENTION

Flame retardant resin compositions, useful, for example, in laminates,composites and the like, and articles prepared from said composition areprovided. One embodiment relates to a composition comprising:

-   -   a) an epoxy resin, and    -   b) a phosphorus containing flame retardant material obtained by        heating at temperatures of 200° C. or higher, e.g., 220° C. or        higher, generally at temperatures of 250° C. or higher, e.g.        from about 250° C. to about 400° C. or from about 260° C. to        about 360° C., one, or more than one, phosphonic acid salt,        i.e., compounds of formula (I)

-   -   wherein R is an alkyl, aryl, alkylaryl or arylalkyl group, p is        a number of from 1 to 7, e.g., from 1 to 4, e.g., 1, 2, 3 or 4,        M is a metal, y is a number of from 1 to 7, e.g., from 1 to 4,        e.g., 1, 2, 3 or 4, often 2 or 3, so that M^((+)y) is a metal        cation where (+)y represents the charge formally assigned to the        cation.

Further embodiments of the invention provide a curable composition,e.g., a halogen free composition, comprising a) an epoxy resin, b) theflame retardant above, and c) a cross-linker; the curable compositionfurther comprising d) one or more additional flame retardants, flameretardant synergists and/or flame retardant adjuvants; the cured epoxycompositions produced therefrom, and articles comprising thecompositions, such as molded articles, laminates, composites and thelike, for example, prepregs useful in the construction of printedcircuit boards and the circuit boards comprising said prepregs.

DESCRIPTION OF THE INVENTION

Materials useful as the flame retardant b) in the present compositioncan be found, e.g., in copending U.S. patent application Ser. Nos.14/337,500 and 14/592,472, and methods for preparing the material can befound therein. In general, the flame retardant material of b) isobtained by heating at temperatures of 200° C. or higher, e.g., 220° C.,often 250° C. or higher, one, or more than one, phosphonic acid salt,i.e., compounds of formula (I)

-   -   wherein R is an alkyl, aryl, alkylaryl or arylalkyl group, p is        a number of from 1 to 7, e.g., from 1 to 4, e.g., 1, 2, 3 or 4,        M is a metal, y is a number of from 1 to 7, e.g., from 1 to 4,        e.g., 1, 2, 3 or 4, often 2 or 3, so that M^((+)y) is a metal        cation where (+)y represents the charge formally assigned to the        cation.

In formula (I), M^((+)y) where y is 1 represents a mono-cation such asLi⁺, Na⁺ or K⁺, Me^((+)y) where y is 2 represents a di-cation such asMg⁺⁺, Ca⁺⁺ or Zn⁺⁺ and the like, Me^((+)y) where y is 3 represents atri-cation such as Al⁺⁺⁺, etc. As is common with organometallic species,the formulae are idealized and the starting materials may includecomplex salts or salts where certain atomic valences are shared such aswhere a single oxygen anion is shared between two metal cations, etc.Typically, the starting salt is charged balanced, that is, a compound offormula (I) wherein p=y, e.g., when Me^((+)y) is Na⁺, p is 1, when M isAl⁺⁺⁺ p is 3, etc.

The flame retardants above are obtained by thermal conversion of thephosphonic acid salts of formula I before incorporation into thesubstrate being rendered flame retardant. As shown, for example, in U.S.patent application Ser. No. 14/337,500, salts of formula (I) are notthemselves stable at high temperatures and attempts to incorporate thecompounds of formula (I) directly into polymers at elevated temperaturescan cause damage such as polymer degradation and a loss of physicalproperties.

Not wanting to be bound by theory, analytical data suggest that thematerial generated by heating compounds of formula (I) at the listedtemperature comprises a compound or a mixture of compounds one or moreof which is believed to be generically represented by the empiricalformula (IV):

wherein R and M are as defined for formula (I), q is a number of from 1to 7, e.g., 1, 2 or 3, r is a number from 0 to 5, e.g., 0, 1 or 2, often0 or 1, y is a number of from 1 to 7, e.g., from 1 to 4, e.g., 1, 2, 3,or 4, and n is 1 or 2, provided that 2(q)+r=n(y). It is believed thatmore than one compound is typically present in the material sogenerated.

The phosphonic acid salts of formula (I) are known and various methodsfor their preparation are described in the art. For example, US2006/0138391 discloses compounds of formula (I) wherein R is hydrogen,C₁₋₁₈ alkyl, C₅₋₆cycloalkyl, C₂₋₆ alkenyl, C₆₋₁₀ aryl, or C₇₋₁₁ aralkyl,which alkyl, alkenyl, aryl, or aralkyl can be unsubstituted orsubstituted by halogen, hydroxyl, amino, C₁₋₄ alkylamino, di-C₁₋₄aalkylamino, C₁₋₄ alkoxy, carboxy or C₂₋₅alkoxycarbonyl; and M can beselected from, e.g., Group IA, IB, IIA, IIB, IIIA, IVA, VA or VII of thePeriodic Table, for example Li, K, Na, Mg, Ca, Ba, Zn, Ge, B, Al, Cu,Fe, Sn or Sb, etc. It is noted that in US 2006/0138391 none of thecompounds corresponding to the formula (I) above were heated above 200°C. or compounded into a polymer resin at elevated temperature.

In some embodiments of the invention, the salts of formula (I) comprisecompounds wherein R is C₁₋₁₂ alkyl, C₆₋₁₀ aryl, C₇₋₁₈ alkylaryl, orC₇₋₁₈ arylalkyl group, wherein said groups are further substituted asdescribed in US 2006/0138391, but often R is unsubstituted C₁₋₁₂ alkyl,C₆₋₁₀ aryl, C₇₋₁₈ alkylaryl, or C₇₋₁₈ arylalkyl. For example, R issubstituted or unsubstituted, typically unsubstituted, C₁₋₆ alkyl, C₆aryl, C₇₋₁₀ alkylaryl, or C₇₋₁₂ arylalkyl, e.g., C₁₋₄ alkyl, C₆ aryl,C₇₋₁₉ alkylaryl, or C₇₋₁₀ arylalkyl.

While in the most general embodiments of the invention M^((+)y) may bealmost any metal cation, M is generally selected from Li, K, Na, Mg, Ca,Ba, Zn, Zr, Ge, B, Al, Si, Ti, Cu, Fe, Sn or Sb, for example, e.g., Li,K, Na, Mg, Ca, Ba, Zn, Zr, B, Al, Si, Ti, Sn or Sb, in many embodimentsM is Li, K, Na, Mg, Ca, Ba, Zn, Zr, B, Al, Sn or Sb, and in certainembodiments M is Al, Zn or Ca. For example, excellent results areachieved when M is Al or Ca.

R as alkyl is a straight or branched chain alkyl group having thespecified number of carbons and includes e.g., unbranched alky such asmethyl, ethyl, propyl, butyl, pentyl, hexyl heptyl, octyl, nonyl, decyl,undecyl, dodecyl, and unbranched alkyl such as iso propyl, iso-butyl,sec-butyl, t-butyl, ethyl hexyl, t-octyl and the like. For example, R asalkyl is methyl, ethyl, propyl, iso propyl, butyl, iso butyl, sec-buty,t-butyl, often R is methyl, ethyl, propyl or isopropyl, for examplemethyl.

Typically, when R is aryl it is phenyl or naphthyl, for example, phenyl.Examples of R as alkylaryl include phenyl substituted by one or morealkyl groups, for example groups selected from methyl, ethyl, propyl,isopropyl, butyl, iso butyl, sec-buty, t-butyl, and the like. Examplesof R as arylalkyl, include for example, benzyl, phenethyl, styryl,cumyl, phenpropyl and the like.

In one embodiment R is methyl, ethyl, propyl, isopropyl, phenyl orbenzyl, e.g., methyl or phenyl.

In certain embodiments, for example, the starting material is one ormore compounds of formula (I) wherein R is methyl, ethyl, propyl,isopropyl, benzyl or phenyl, M is Al, Zn or Ca, and p is 2 or 3. In oneparticular embodiment R is methyl, ethyl, propyl, isopropyl, or phenyl,p=3 and M is Al; in another particular embodiment R is methyl, ethyl,propyl, isopropyl, or phenyl, p=2 and M is Zn or Ca, e.g., Ca.

Typically, thermal treatment of a compound of formula (I) as abovegenerates a material comprising more than one compound, at least one ofwhich is believed to be generically represented by the empirical formula(IV) and complex dehydration products thereof. As is common withorganometallic species, the formula (IV) is idealized and the productmay include polymeric salts, complex salts, salts where certain atomicvalences are shared, etc.

For example, when M is aluminum, i.e., when a compound of formula (I)wherein M is Al is heated according to the invention, elemental analysissuggests the formation of a product having an empirical formula (IV)wherein q is 1, r is 1, n is 1 and y is 3.

When formed from a compound of formula (I) wherein one R group and onemetal is present, a mixture of compounds typically forms comprising atleast one compound of formula (IV), wherein said mixture and saidcompound or compounds of formula (IV) comprise the one R group and theone metal. In some embodiments of the invention, the flame retardantmaterial comprises a mixtures of compounds wherein more than one R groupand/or more than one metal is present, and wherein a mixture ofcompounds of formula (IV) comprising more than one R group and/or morethan one metal is present. Flame retardants of the invention comprisingcompounds containing more than one R groups and/or more than one metalcan be formed in various ways.

In a first method, which can be called the intermediate salt complexmethod, one or more phosphonic acid compounds are treated with one ormore appropriate metal compounds to give an intermediate salt complexcorresponding to formula (I), which complex comprises multiple valuesfor R and/or M. Often the metal, or at least one of the metals used informing the intermediate salt complex will be a bidentate or polydentatemetal and more than one intermediate complex may be formed. This saltcomplex is then heat-treated as described above to obtain a flameretardant material comprising:

a) at least one compound corresponding to formula (IV) having more thanone than one R group and/or more than one M group, and/or

b) a mixture of compounds corresponding to formula (IV) are present saidmixture comprising compounds with different R groups and/or different Mgroups.

Alternatively, in a second method, which can be called the intimate saltmixture method, two or more metal phosphonic acid salts of formula (I)are brought together to form an intimate salt mixture comprising saltswhich have differing values for R and/or M. This mixture is thensubjected to heat treatment described above to obtain a flame retardantmaterial comprising:

a) at least one compound corresponding to formula (IV) having more thanone than one R group and/or more than one M group, and/or

b) a mixture of compounds corresponding to formula (IV) are present saidmixture comprising compounds with different R groups and/or different Mgroups.

A third method for obtaining flame retardant materials of the inventioncomprising compounds of formula (IV) having multiple values for R and/orM comprises separately heating two or more individual metal phosphonicacid salts of formula (I), which differ by having different values for Rand/or M, as described above to separately obtain two or more flameretardant materials of the invention, which are subsequently mixedtogether to form a blended flame retardant composition.

The exact composition the mixtures obtained by the preceding threeprocesses, i.e., the intermediate salt complex method, the intimate saltmixture method, and the blending of separately obtained flame retardantmaterials, will generally be different even when starting from the samephosphonic acid compounds and metals. Thus, differences in physicalcharacteristics, stability, miscibility and performance for the productsof the different methods are generally encountered.

In many embodiments of the invention, the epoxy resin composition willcomprise flame retardants in addition to those of component b) asdescribed above, as well as synergists, adjuvants and other commonadditives.

In the broadest embodiments on the invention any suitable epoxy resinmay be used in component a), e.g., the epoxy resin material may be anysaturated or unsaturated aliphatic, cycloaliphatic, aromatic orheterocyclic compound which possesses more than one 1,2-epoxy group.Many examples of which are described in Epoxy Resins Chemistry andTechnology, Second Edition edited by Clayton A. May (Marcel Dekker, Inc.New York, 1988), Chemistry and Technology of Epoxy Resins edited by B.Ellis (Blackie Academic & Professional, Glasgow, 1993), Handbook ofEpoxy Resins by H. E. Lee and K. Neville (McGraw Hill, New York, 1967),and EP 1116774 A2. More than one epoxy resin may be present.

Suitable epoxy resins include, but are not limited to, epoxy resinsbased on bisphenols and polyphenols, such as, bisphenol A,tetramethylbisphenol A, bisphenol F, bisphenol S,tetrakisphenylolethane, resorcinol, 4,4′-biphenyl, dihydroxynaphthylene,and epoxy resins derived from novolacs, such as, phenol:formaldehydenovolac, cresol:formaldehyde novolac, bisphenol A novolac, biphenyl-,toluene-, xylene, or mesitylene-modified phenol:formaldehyde novolac,aminotriazine novolac resins and heterocyclic epoxy resins derived fromp-amino phenol and cyanuric acid. Additionally, aliphatic epoxy resinsderived from 1,4-butanediol, glycerol, and dicyclopentadiene skeletons,are suitable. Examples of heterocyclic epoxy compounds arediglycidylhydantoin or triglycidyl isocyanurate. Many other suitableepoxy resin systems are available and would also be recognized as beingsuitable by one skilled in the art. For example, epoxy resins comprisinga phosphorus moiety are known and may be used in some embodiments of theinvention. Epoxy compounds comprising phosphorus containing moietiesinclude, for example, alkyl, alkenyl, aromatic and benzylic diglycidylphosphonates, phosphates and thiophosphates, triglycidyl andtris-alkylglycidyl phosphates, DOPO-based epoxy resins, etc., many ofwhich can be found U.S. Pat. No. 5,376,453.

In some embodiments an epoxy resin comprising a phosphorus flameretardant moiety may be present. In such a case, a lower concentrationof the flame retardant material described above for component b) may beneeded to achieve the desired flame retardancy.

For example, U.S. Pat. No. 6,403,220 and U.S. Pat. No. 6,645,631disclose useful phosphorus containing epoxy resins, many of whichcomprises phosphorus flame retardant moieties, obtained by reacting anepoxy resin, such as an epoxy novolac, a dicyclopentadiene phenol epoxynovolac; a glycidyl of tetraphenolethane; a diglycidyl ether ofbisphenol-A; or a diglycidyl ether of bisphenol-F and the like with aphosphorus element-containing compound such as a phosphite, a phosphinicacid, or compounds such as9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide;10-(2′,5′-dihydroxyphenyl)-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide;bis(4-hydroxyphenyl)phosphine oxide; tris(2-hydroxyphenyl)phosphineoxide; dimethyl-1-bis(4-hydroxyphenyl)-1-phenylmethylphosphonate;tris(2-hydroxy-4/5-methylphenyl)phosphine oxide;tris(4-hydroxyphenyl)phosphine oxide,bis(2-hydroxyphenyl)phenylphosphine oxide,bis(2-hydroxyphenyl)phenylophosphinate,tris(2-hydroxy-5-methylphenyl)phosphine oxide; amino functionalcompounds such as bis(4-aminophenyl)phenylphosphate and the like.

Examples of useful epoxy resins comprising hydroxyaryl phosphine oxideflame retardants are also disclosed in U.S. Pat. Nos. 6,733,698;8,404,161; and 8,865,862, obtained by reaction of, e.g., (2-hydroxyphenyl)phosphine oxides or other similar materials, with glycidyl orpolyglycidyl ethers, epihalohydrins etc.

Other examples of resins useful in the present invention include thosedescribed in WO 99/00451 and U.S. Pat. No. 5,112,931, such as an epoxyresin which is the reaction product of an epoxy compound containing atleast two epoxy groups and a chain extender, for example, anepoxy-polyisocyanate adduct or an epoxy-terminated polyoxazolidone. Theisocyanate compounds as chain extenders include for example MDI, TDIetc.

It is generally advantageous to use an epoxy resin which possessesaverage more than 1 and preferably at least 1.8, more preferably atleast 2 epoxy groups per molecule. In many embodiments of the presentinvention, the epoxy resin (a) is a non-halogenated epoxy resinmaterial.

In many embodiments the composition will comprise a non-halogenated,non-phosphorus element-containing epoxy resin, which has no alkylaliphatic substituents or has a low amount of alkyl aliphaticsubstituents, such as for example the glycidyl ether of a phenolnovolac, or the glycidyl ether of bisphenol-F, the glycidyl ether ofbisphenol-S, bisphenol-A, or dihydroxyl ether of fluorene 9-bisphenyl;or trisepoxy, or dicyclopentadiene modified phenol epoxy resin, ormixtures thereof.

For example, the epoxy resin is an epoxy novolac resin (sometimesreferred to as epoxidized novolac resins, a term which is intended toembrace both epoxy phenol novolac resins and epoxy cresol novolacresins), which are readily commercially available. For example, anovolac epoxy resin with at least 2.5 epoxy groups per molecule.

Generally, the epoxy resin (a) is used in an amount of from about 30 wt% to about 95 wt %. More than one epoxy resin may be present in thecomposition.

Curable epoxy resin formulations comprise a hardener, cross-linker orcuring agent. For example, the epoxy resins and can be cured withstandard hardeners such as a combination of dicyandiamide and2-methylimidazole. The terms “hardener”, “cross-linker”, and “curingagent” are often used interchangeably in the art, and as used hereinalso encompasses materials or compounds which form a cross linker suchas a phenolic cross linker upon heating. Likewise, the term “catalyst”as used in relation to curable epoxy resins is used interchangeably withthe term “accelerant”.

Materials useful as cross linkers in the present invention includephenolic cross linking agents having a functionality of at least 2 andinclude compounds, either polymeric or monomeric, having at least 2phenolic-OH (hydroxyl groups) capable of reacting with epoxy groups. Forexample, hydroxyaryl hardeners useful in the present invention include,but are not limited to, phenolic resins obtained from the reaction ofphenols or alkyl-substituted phenols with formaldehyde, such as phenolnovolaks, cresol novolaks, and resoles. Monomeric hydroxyarylcross-linkers include 3,4,5-trihydroxybenzoic acid (also known as gallicacid) or its derivatives, or pyrogallol (also known as1,2,3-trihydroxybenzol), or 1,2,4-trihydroxybenzol (also known ashydroxyhydrochinon); 1,8,9-trihydroxyanthracene,1,2,10-trihydroxyanthracene; 2,4,5-trihydroxypyrimidine;tris(hydroxyphenyl)methane; tetraphenolethane; and the like.

Many cross-linkers are compounds that are also used in the preparationof certain epoxy resins, e.g., the navolaks above and the phosphoruscontaining compounds useful as cross-linkers, that can be converted intoepoxy resins as described in U.S. Pat. No. 6,403,220; U.S. Pat. Nos.6,645,631; 6,733,698; 8,404,161; and 8,865,862.

Other useful curing agents include amines and compounds derived fromamines. Amine hardeners include, but are not limited to, alkyl amines,aryl amines, amides, biguanide derivatives, melamine and guanaminederivatives, imidazoles, polyamides, polyamidoamines, imidazolines,araliphatic amines, polyamines such as polyetheramines, and the like.Examples of amine or amine derived curing agents include dicyandiamide,substituted dicyandiamide, m-phenylenediamine, methylene-dianiline,diaminodiphenylsulfone, ethylenediamine, diethylenetriamine,sulfanilamide, 2,4-diamino-6-phenyl-1,3,5 triazine, bismaleic triazines,cyanate esters such as dicyanate of dicyclopentadienyl bisphenol,dicyanate of bisphenol-A, isocyanates such as MDI, TDI and the like, asfound in art, e.g., WO 99/00451.

The epoxy resins may also be cured by the action of combinationsinvolving amines with Lewis acids. Combinations of nitrogen-containinghardeners with Lewis acids include the heterocyclic secondary andtertiary amines and the Lewis acids include oxides and hydroxides ofzinc, tin, silicon, aluminum, boron, and iron.

Examples of compounds which form a cross linking agent upon heatinginclude benzoxazine and derivatives of benzoxazine. Examples includebenzoxazine of phenolphthalein, benzoxazine of bisphenol-A, benzoxazineof bisphenol-F, benzoxazine of phenol novolac and the like.

Other curing agents include carboxylic acids and anhydrides,amino-formaldehyde resins, and amine-boron complexes. Many types ofcuring agents that would be useful can be found in any basic epoxy resintext and include, e.g., anhydrides such as a carboxylic acid anhydrides,styrene maleic anhydride copolymers, maleic anhydride adducts ofmethylcyclopentadiene and the like; carboxylic acids such as salicylicacid, phthalic acid and the like;

In many embodiments the curing agent will comprise a phenolic crosslinker, such as a novolak compound or resin, or an amine or aminederivative, such as dicyandiamide, a substituted dicyandiamide, anaromatic diamine or a cyanate ester.

Formulating an epoxy resin with an appropriate amount of curing agent iswell within the ability of one skilled in the art. For example, thecuring agent may be a hydroxy functional cross linker, such as a novolacresin etc., and the composition comprises from about 50 to about 150% ofthe stoichiometric amount of hydroxy groups needed to cure the epoxyresin. In some embodiments, the amount of crosslinker is from about 80to about 125% of the stoichiometric amount of hydroxy groups needed tocure the epoxy resin. In some embodiments the curing agent may be adiamine, a polyamine, a dicyandiamide or a substituted dicyandiamide andthe composition comprises from about 50 to about 150%, e.g., from about80 to about 125%, of the stoichiometric amount of reactive nitrogensgroups needed to cure the epoxy resin. The same principals apply forother crosslinking materials, more than one of which may be used.

Combinations of amine catalysts with Lewis acids, especially boroncompounds such as BF₃, boric acid and derivatives thereof, have longbeen used in the curing of epoxy resins, and methods for their use arereadily found in the art, e.g., U.S. Pat. No. 6,645,631.

In particular embodiments of the invention the epoxy resin compositionsare used in the preparation of composite materials and articles such aslaminates. A specific example of such an application is in theproduction of electrical laminates used in printed circuit boards(printed wiring boards, PWB).

As mentioned above, U.S. Pat. No. 6,403,220 and U.S. Pat. No. 6,645,631describe process for preparing electrical laminates in which (1) anepoxy-containing formulation is applied to or impregnated into asubstrate, which substrate is then (2) heated to draw off solvent in theepoxy formulation and optionally to partially cure the epoxy formulationforming a prepreg, followed by (3) stacking one or more sheets ofprepreg in alternating layers with one or more sheets of a conductivematerial, such as copper foil, and pressed at elevated temperature andpressure for a time sufficient to fully cure the resin and form alaminate. The heating process of step (2) to produce the prepreg isknown as “B-staging” and typically occurs at temperatures from about 90°C. to about 210° C. for a time ranging from about 1 minute to about 15minutes. Other temperatures and times are sometimes be used.

A typical requirement for these laminates, and many other applications,is flame resistance and a fire retardancy level of V-0 in the standard“Underwriters Laboratory” test method UL 94. The epoxy resincompositions of the invention can meet these requirements without theuse of halogen containing compounds such as tetrabromobisphenol A.

One difficulty encountered in the art in preparing the above laminatesis that some curable epoxy compositions have gel times as observed bythe stroke cure test, of less, sometimes much less, than 180 seconds,which complicates the production of prepregs in forming the laminates.Gel times greater than 180 seconds, for example 250 seconds, for example300 seconds or greater are more desirable and are readily obtained usingthe present invention.

It is found that many of the epoxy resin compositions of the inventionare well suited for the production of laminates with stringentrequirements for flame retardancy, such as, electrical laminates and theprepregs used in their manufacture, due in large part to the ability ofthe flame retardants of component b) to provide the necessary flameretardancy without speeding or slowing the cure time of the resin. Thisallows for one to prepare the prepreg under consistent and controllableprocessing conditions without the complications of an unexpectedly shortworking window or an under cured resin. The present flame retardants arealso stable under demanding conditions, including high temperatures andexhibit negligible negative impact on the physical properties of thecured resin.

Certain particular embodiments of the invention therefore are to epoxyresin compositions useful in preparing laminates and the laminates thusprepared. Specific embodiments relate to epoxy resin compositions of theinvention useful in preparing electrical laminates, the process ofpreparing the laminates using said epoxy resin compositions, prepregsformed using the epoxy resin compositions, and the electrical laminatesproduced therefrom, for example, electrical laminates prepared from afibrous reinforcement and an epoxy-containing matrix resin of theinvention, and prepregs comprising e.g., a woven or nonwoven fiber mat,e.g., a substrate comprising glass fibers or paper, a cured, semi-cured,or non-cured epoxy resin composition of the invention.

Other more general embodiments relate to flame retardant epoxycompositions that allow for greater control over the cure time or thegel time of the resin.

Resins, other than epoxy resins, can be used in the production ofcomposites and laminates generally, and in the production of circuitboards and prepregs in a manner analogous to that described above. Manysuch resins are known in the art, which can be used as part of a blendwith epoxy resins or in the absence of epoxy resins. Certain embodimentsof the invention therefore provide resin compositions comprising theflame retardant b) and one or more base resins, in the presence of, orin the absence of, the epoxy resins described above; the use of suchcompositions in the manufacturing of prepreg and laminate materials,e.g., electrical laminates; and the prepregs and laminates somanufactured. These non-epoxy resins are often found in very demandingapplications with stringent physical, thermal and electricalrequirements; non-limiting examples of such resins include cyanateresins, bismaleimide resins, polyimide resins, phenolic resins, furanresins, xylene formaldehyde resins, ketone formaldehyde resins, urearesins, melamine resins, aniline resins, alkyd resins, unsaturatedpolyester resins, diallyl phthalate resins, triallyl cyanate resins,triazine resins, polyurethane resins, polyolefin resins, polyphenyleneether resins, benzocyclobutene resins, benzoxazine resins, siliconeresins and any combination or mixture thereof.

The concentration of the flame retardant b) in the resin composition isof course dependent on the exact chemical composition of the flameretardant, the epoxy resin and other components found in the finalcomposition. For example, flame retardant b) may be present in aconcentration of from about 1 to about 60%, e.g., 1 to 55%, 1 to 50%, 1to 35%, by weight of the total weight of the final composition, butconcentrations higher than 60% are possible. Typically there will be atleast 2% of flame retardant b) present, for example 3% or more, 5% ormore, 10% or more, 15% or more, 20% or more or 25% or more. In manyembodiments, flame retardant b) is present in amounts up to 45%, whilein other embodiments, the amount of inventive flame retardant is 40% ofthe polymer composition or less, e.g., 35% or less, or 30% or less.Obviously, when used in combination with other flame retardants or flameretardant synergists, less of flame retardant b) should be needed.

In many embodiments the composition according to the invention comprisesa) the epoxy resin, b) the phosphorus containing flame retardantmaterial obtained by heating one, or more than one of the abovedescribed phosphonic acid salt of formula (I), (c) a curing agent and(d) one or more additional flame retardant, synergist, and/or flameretardant adjuvant.

Other flame retardants, synergist or adjuvants may be present in anamount that provides the desired improvement in processing and physicalproperties of the composition. In some compositions only a small amountof component c) will necessary, e.g., 1%, 2%, 3%, 4% or 5% based on thetotal weight of the composition, in other embodiments, 10%, 15%, 20%,25% or more may be employed.

For example, the flame retardant polymer composition of the inventionmay comprise other flame retardants such as alkyl or aryl phosphineoxide flame retardants, alkyl or aryl phosphate flame retardants, alkylor aryl phosphonates, alkyl or aryl phosphinates, and salts of alkyl oraryl phosphinic acid, e.g., an aluminum tris(dialkylphosphinate) such asaluminum tris(diethylphosphinate). In some embodiments halogenated flameretardants may also be present, but in most embodiments of theinvention, halogenated flame retardants, are excluded.

For example, flame retardant polymer composition of the invention mayfurther comprise one or more materials selected from:

carbon black, graphite, carbon nanotubes, silicones; polyphenylene ether(PPE), phosphine oxides and polyphosphine oxides, e.g., benzylicphosphine oxides, poly benzylic phosphine oxides and the like;

melamine, melamine salts, melamine derivatives and condensation, suchas, but not limited to, melam, melem, melon, melamine cyanurate,melamine borate, melamine phosphates, melamine metal phosphates, and thelike;

inorganic compounds including clays, metal salts such as hydroxides,oxides, oxide hydrates, borates, carbonates, sulfates, phosphates,phosphites, hypophosphites, phosphinites, silicates, mixed metal salts,etc., e.g., talc and other magnesium silicates, calcium silicate,aluminosilicate, aluminosilicate as hollow tubes (DRAGONITE), calciumcarbonate, magnesium carbonate, barium sulfate, calcium sulfate,HALLOYSITE or boron phosphate, calcium molybdate, exfoliatedvermiculite, zinc stannate, zinc hydroxystannate, zinc sulfide and zincborate, zinc molybdate (KEMGARD 911A/B), zinc phosphate (KEMGARD 981),magnesium oxide or hydroxide, aluminum oxide, aluminum oxide hydroxide(Boehmite), aluminum trihydrate, silica, tin oxide, antimony oxide (IIIand V) and oxide hydrate, titanium oxide, and zinc oxide or oxidehydrate, zirconium oxide and/or zirconium hydroxide and the like.

Unless otherwise specified, in the context of the present application,the term “phosphate” when used as a component in a “phosphate salt”,such as in metal phosphate, melamine phosphate, melamine metalphosphate, etc., refers to a phosphate, hydrogen phosphate, dihydrogenphosphate, pyrophosphate, polyphosphate, or a phosphoric acidcondensation products anion or polyanion.

Likewise, unless otherwise specified, in the context of the presentapplication, the term “phosphite” when used as a component in a“phosphite salt”, such as in metal phosphite, etc., refers to aphosphite or hydrogen phosphite.

In some particular embodiments the flame retardant polymer compositioncomprises one or more synergists or flame retardant adjuvants, e.g.,melamine, melamine salts, melam, phosphine oxides and polyphosphineoxides, metal salts such as hydroxides, oxides, oxide hydrates, borates,phosphates, phosphites, silicates and the like, e.g. aluminum hydrogenphosphite, a melamine metal phosphate, e.g., a melamine metal phosphatewherein the metal comprises aluminum, magnesium or zinc. In particularembodiments the one or more additional flame retardant, synergist orflame retardant adjuvant comprises an aluminum tris(dialkylphosphinate)such as aluminum tris(diethylphosphinate), aluminum hydrogen phosphite,methylene-diphenylphosphine oxide-substituted polyaryl ether,xylylenebis(diphenylphosphine oxide),4,4′-bis(diphenylphosphinylmethyl)-1,1′-biphenyl, ethylenebis-1,2-bis-(9,10-dihydro-9-oxy-10-phosphaphenanthrene-10-oxide)ethane,melem, or dimelamine zinc pyrophosphate.

When present, an additional flame retardant, synergist or adjuvant d) ispresent in a range of 100:1 to 1:100 by weight of flame retardant b) tothe total weight of additional flame retardant, synergist and adjuvant.Depending on the additional flame retardant, synergist or adjuvant,excellent results can be obtained using a range of 10:1 to 1:10 byweight of flame retardant b) to additional flame retardant, synergistand/or adjuvant, for example, weight ratios ranging from 7:1 to 1:7, 6:1to 1:6, 4:1 to 1:4, 3:1 to 1:3 and 2:1 to 1:2 are used to good benefit.

The flame retardant epoxy resin composition of the invention will alsotypically contain one or more of the common stabilizers or otheradditives frequently encountered in the art including stabilizers,fillers, reinforcing agents, emulsifiers, pigments, dyes, opticalbrighteners, anti-static agents, anti-drip agents, etc., e.g., materialssuch as PTFE, ultraviolet light absorbers, hydrotalcites, metal oxides,borates, alkali metal salts and alkaline earth metal salts and the like.

Fillers and reinforcing agents that may be present, include, e.g., glassfiber, glass fabrics, glass matt, milled glass fiber, glass beads (solidor hollow), metal compounds and clays such as calcium carbonate,silicates, glass fibers, talc, kaolin, bentonite, mica, barium sulfate,metal oxides and hydroxides, carbon black, graphite, wollastonite,silica, silicon carbide whiskers and so forth. Many of these materialsare described in standard industry texts such as the Encyclopedia ofMaterials Science and Engineering, Vol. #3, pp. 1745-1759, MIT Press,Cambridge, Mass. (1986). Combinations of fillers may be used in someembodiments.

Such fillers and reinforcing agents may often be present at relativelyhigh concentrations, including formulations where the filler orreinforcement is present in concentrations of over 50 wt % based on theweight of the final composition. More typically, fillers and reinforcingagents are present from about 5 to about 50 wt %, e.g., about 10 toabout 40 wt % or about 15 to about 30 wt % based on the weight of thetotal polymer composition. In prepregs and laminates for printed wiringboards, reinforcing agents such as glass fabric, may be the substrate towhich the composition is applied and in some embodiments, thereinforcing agent makes up most of the final composite.

The epoxy compositions are prepared by combining the componentsaccording to techniques well-known to one familiar with the art. Inertsolvents may be used in preparing the compositions and may be present inthe composition when it is applied to a substrate, or introduced into amold. Curing is accomplished in a common manner, e.g., by heating thecomposition. In some embodiments, a curing catalyst is present in thecomposition during cure.

EXAMPLES

Flame retardant resin compositions can be prepared using methods knownin the art or variations thereof and used in the preparation of prepregsand laminates in a manner generally analogous to procedures known in theart, e.g., U.S. Pat. Nos. 6,403,220 and 6,645,631.

General Example

An epoxy resin based formulation containing one or more epoxy resins, acatalyst, and a curing agent, such as a novolac resin or an amine-basedcuring agent, can be mixed according to known methods with aflame-retarding level of a flame retardant from US 20150031805, i.e.,copending U.S. patent application Ser. No. 14/337,500, e.g., the flameretardant from Example 1 from US 20150031805, prepared by thermaltreatment of methylphosphonic acid aluminum salt, to make a resinvarnish. The varnish is then coated onto glass fabric and B-staged in anoven to generate prepregs, which are then stacked 8-ply and pressed atelevated pressure and temperature to form a uniform laminate capable ofobtaining a flammability rating of V-0 per the UL-94 test.

Flame Retardant from Methylphosphonic Acid Aluminum Salt

A solution of methylphosphonic acid in deionized water is added aluminumethoxide under nitrogen, stirred for 16 h, concentrated and dried at 100C in vacuo providing a clear, colorless solid that was heated for 4 h at280° C. according to the process of Example 1 from US 20150031805 toyield the flame retardant.

FR Test Results from Laminates 1 and 2

An epoxy resin stock solution prepared from a 1:1 w/w mixture of DEN-438and EPDXYHARZ C in acetone was mixed in appropriate ratio with a novolacresin stock solution prepared from SD-1708 in a similar manner.2-methylimidazole (2Ml) was added and dissolved. To this mixture wasadded the Flame Retardant from Methylphosphonic Acid Aluminum Salt aboveto make the final formulation varnish. Amounts of each component areshown in Table 1 below.

TABLE 1 Material Laminate 1 Laminate 2 DEN-438 (g) 70.0 65.0 EPOXYDHARZC (g) 70.0 65.0 SD-1708 (g) 77.2 71.6 Flame Retardant (g) 54.3 86.4 2-MI(g) 0.19 0.245

The varnish mixture was vigorously shaken in a bottle and the viscositywas adjusted as needed with acetone. The varnish was coated onto eightplies of 7628 glass fabric and B-staged at 170° C. The resultingprepregs were stacked 8-ply and pressed at 195° C. to give a laminateboard. The laminate was cut into test specimens and tested according toUL-94 flammability test protocol. Results are shown in Table 2 below.

TABLE 2 UL-94 Test Laminate 1 Laminate 2 Bar 1 (T1/T2), sec 1, 9  0, 6Bar 2 (T1/T2), sec 0, 0  0, 7 Bar 3 (T1/T2), sec 1, 8  0, 8 Bar 4(T1/T2), sec 0, 13 0, 6 Bar 5 (T1/T2), sec 0, 11 0, 2 Total burn time,sec 43 29 Rating V-1 V-0

Excellent flammability performance is observed, achieving V-0performance for Laminate 2 and nearly V-0 performance for Laminate 1.

What is claimed:
 1. A flame retardant resin composition comprising a) acyanate resin, bismaleimide resin, polyimide resin, phenolic resin,furan resin, xylene formaldehyde resin, ketone formaldehyde resin, urearesin, melamine resin, aniline resin, alkyd resin, unsaturated polyesterresin, diallyl phthalate resin, triallyl cyanate resin, triazine resin,polyphenylene ether resin, benzocyclobutene resin, or benzooxazineresin, b) from 1% to 60%, by weight based on the total weight of theflame retardant resin composition, of a flame retardant materialcomprising products of thermal conversion of one or more than onecompound of formula (I) before incorporation into the resin of componenta), said products being obtained by a process comprising heating attemperatures of about 200° C. or higher from about 0.01 hour to about 20hours one or more than one compound of formula (I)

wherein R is C₁₋₁₂ alkyl, C₆₋₁₀ aryl, C₇₋₁₈ alkylaryl, or C₇₋₁₈arylalkyl, wherein said alkyl, aryl, alkylaryl, or arylalkyl areunsubstituted or are substituted by halogen, hydroxyl, amino, C₁₋₄alkylamino, di-C₁₋₄ alkylamino, C₁₋₄ alkoxy, carboxy orC₂₋₅alkoxycarbonyl; M is a metal, y is a number of from 1 to 4 so thatM^((+)y) is a metal cation where (+)y represents the charge formallyassigned to the cation, and p is a number of from 1 to 4, and c) acuring agent, wherein the flame retardant resin exhibits a V-1 or V-0rating using the “Underwriters Laboratory” test method UL
 94. 2. Theflame retardant resin composition according to claim 1 wherein the flameretardant material (b) comprises at least one compound corresponding toformula (IV) having more than one than one R group and/or more than oneM group,

wherein R is as defined above, q is 1, 2 or 3, r is 0, 1 or 2, y is 1,2, 3, or 4, and n is 1 or 2, provided that 2(q)+r=n(y), and is obtainedby a process comprising: i) preparing an intermediate salt complex bytreating one or more phosphonic acid compound with one or moreappropriate metal compound to give an intermediate salt complexcorresponding to formula (I) comprising multiple values for R and/or M,and then heating the intermediate salt complex at temperatures of about200° C. or higher for about 0.01 hour to about 20 hours; or ii)preparing an intimate salt mixture by combining two or more individualmetal phosphonic acid salts of formula (I) which have differing valuesfor R and/or M, and then heating the intimate salt mixture attemperatures of about 200° C. or higher for about 0.01 hour to about 20hours.
 3. The flame retardant resin composition according to claim 1wherein M in formula (I) is Li, K, Na, Mg, Ca, Ba, Zn, Zr, B, Al, Si,Ti, Sn or Sb.
 4. The flame retardant resin composition according toclaim 1 wherein M in formula (I) is Al or Ca.
 5. The flame retardantresin composition according to claim 1 wherein in formula (I) R isunsubstituted C₁₋₆ alkyl, C₆ aryl, C₇₋₁₀ alkylaryl, or C₇₋₁₂ arylalkyl.6. The flame retardant resin composition according to claim 1 furthercomprising d) one or more compounds selected from the group consistingof additional flame retardants, synergists and flame retardantadjuvants.
 7. The flame retardant resin composition according to claim 1wherein the curing agent comprises a phenolic cross linker, a diamine, apolyamine, a dicyandiamide or a substituted dicyandiamide.
 8. The flameretardant resin composition according to claim 1 further comprising oneor more epoxy resins.
 9. The flame retardant resin composition accordingto claim 8 wherein the one or more epoxy resins comprise an epoxynovolac resin.
 10. A laminate comprising a cured flame retardant resincomposition according to claim 1.